This invention relates to “Railway (Rolling Stock), Electronics, Automation, Internet of Things (IoT), Artificial Intelligence, Wireless Communication System, Cloud Computing”.
BACKGROUND OF THE INVENTION
Till in the Railway, for the monitoring and maintenance of Railway tracks the Track mans and the gang mans have to walk over the Railway tracks over many Kilometers in the different tough environmental conditions and they have to monitor the Track defects manually and without manual monitoring they can not find the Rail Track Failure at different locations. In the similar way without manual monitoring they can not find the defects in wheels, axles, bearings and health condition of other bogie parts, they can find these defects & failures only when the Train will be in static condition. They fails to find these defects & failures during running condition of the train. These defects and failure are the main cause of Railway Accidents.
But problem is that, the Maximum of the Railway Accident occurs when the train are running at very high speed and in that condition the Track mans and the gang mans are not able to monitor these defects & failures in the running condition of train and also they are not having any real time health Condition monitoring system through which they can monitor the health of train bogie parts and rail track on their Smartphone in the running condition of trains and also they are not having any artificial intelligence based prior failure detection system though which they can predict the failure at prior time and repair them on time to avoid dangerous accidents and money losses.
That’s why we have developed an artificial intelligence based Real time train condition monitoring system device which we install on the bogie to predict & record the upcoming failure & damages in the railway tracks, wheels, axles and other bogie parts and send its alert on the smartphone of workers with proper location of failure so as to repair the defect on time to avoid accident and money losses.
Till some machines are available which workers installs on the railway track to record defects & fractures in axle, wheel, bearing, etc. But those machines can provide information only when train passes over it, those machine can not be installed on bogie of train and can not provide the regular health information of each second during running and static condition of train both in the real time on the smart phone.
Present invention will solve a big challenge of Railway workers and will save their money, time and efforts.
1. Only manual monitoring problem: Track mans, gang mans and other workers are not have to manual monitor the defects & fractures on Rail Track, wheels, axles, bearings and other bogie parts because this innovated device will regularly monitors & predicts these defects and send its live information on the smart phone of workers.
2. Unwanted movement of workers on Railway tracks: due to invention of this device the workers will not have to move on the railway track unnecessary they have to move only when the invented device will alert on the smart phone to go at a particular location where can be a fracture or failure. Type of defect, location of fracture on track, bogie number every details will be mentioned in that mobile alert.
3. Flat Wheel Detection problem: damaged or defective wheels can be the cause of a big railway accident, so it's necessary to repair and replace them on time to avoid accidents.
4. Upcoming Rail Break Detection problem: detection of rail break or damages at the prior and right time with their location is the big issue which was causing the railway accidents.
5. Hot Axle Hot Wheel & bearing and other bogie parts fractures & vibrations monitoring problem: some times at the high speed of train the Bearing and axle of bogie got breaked due to overheating which causes a danger Accident because at the running condition of train workers cannot monitor the Temperature, vibration, abnormal sound, acceleration, fracture images through high speed camera, and other data. It can be only monitored by our invented device which we set on the bogie frame not by human.
6. Fracture image capturing by high speed resolution camera during running condition of train: manually the human can see the fractures & damages of bogie parts only when the train will be in static condition, but during running condition of train they will not be able to see what fracture & damages are going on in the bogie parts, but in that condition the invented device can capture the fracture images and can send on the smart phone for analysis during running condition of train.
SUMMARY OF THE INVENTION
This summary is provided to introduce a selection of concepts, in a simplified format, that are further described in the detailed description of the invention.
This summary is neither intended to identify key or essential inventive concepts of the invention and nor is it intended for determining the scope of the invention.
Disclosed herein a real time train condition monitoring system (RTTCMS) comprises a microprocessor (101), Transceiver (102), RTC(103), GPS/GSM (104), Accelerometer (105), Proximity Sensor (105), Gyroscope (106), Magneto meter (107), Sound Sensor (108), Thermal Scanners (109), memory card (110), relay (111) , battery (112) and camera (113).; wherein RTTCMS is an Artificial Intelligence based Device fitted on the Bogie of Train for real time monitoring and prediction of upcoming failures in the Wheels, Rail Break & damages and other Bogie Parts and provide their Health Status on the Smartphone of Workers to Avoid Dangerous Accidents and Money losses.

Real time train condition monitoring system is the sensor based innovated Automatic device which we set on the bogie frame which record the different types of data coming from different bogie parts and rail track during running and static condition of train. Data like- Tri-Axial Vibrations of bogie, angular movements, sounds, temperature of bogie parts (wheels, bearings, axles, rail, etc.), Capture figures of fracture and defective parts from inbuilt high speed resolution camera. The device analyse those recorded data with its pre inbuilt database and predict the future upcoming failure through Artificial intelligence and machine learning technology. After detecting the type of failure the device sends an SMS alert on the smartphone and also update the type of failure on the cloud server for monitoring on mobile apps through GSM and wireless technology & IoT.
Due to the invention of this device the track mans and gang mans wearing red and yellow colour dress will not have to walk on the railway track for manual monitoring of fractures on track and also fractures on wheels, axles, bearings, etc. and because they will be informed on their smartphone with fracture location, they will now open the location of fracture on their smartphone app and can easily reach at that location with their bike within a minute for repairing. In this way their time and money will be saved.
The aim of invented device is to detect any type of railway defects and failure before it going to happen so that it can be smartly repaired on time to avoid dangerous accidents. Its aim is to reduce the time of repairing with minimum effort of workers.
In the past the workers have to search the fracture manually by himself and now this invented device will himself monitor the fractures and defects in the track , wheels, bearings, axles, and other bogie parts and send its alert them on the smart phone of workers.
To further clarify advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings.
It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
The foregoing detailed description of embodiments is better understood when read in conjunction with the attached drawings. For better understanding, each component is represented by a specific number which is further illustrated as a reference number for the components used with the figures.
Figure 1: Figure 1 showing the problem faces by Railway workers during manual monitoring & inspection of Rail track Fractures & damages.
Figure 2: figure 2 showing that RTCMS Device fitted on bogie of Train and recording & scanning the data like Temperature, Sound, Vibration, location, time, etc.. in its part 2, it was also showing its industrial use in monitoring Health of big machines.
Figure 3: figure 3 having 2 parts, first is for App View and second is SMS view. In app View you can slide & set the location & time and search, you will find all the details like Vibrations, time, sound, and other data recorded at that time. at which you want to search otherwise it will automatically saved to live location & time.
Figure 4: it was showing that all the Device data coming on workers smartphone in real time.
Figure 5: this figure showing fractures in wheels, creating High Vibration and sounds. Also hammering on Railway track during movement causing track fracture.
Figure 6: it was showing rail fractures
Figure 7: in this figure device scanning the different data coming from the bogie part like- sounds, temperature, vibrations, etc.
Figure 8: it was showing the features you can find on the Smartphone app.
Figure 9: this figure showing the Working model of Device arranged in the form of master & slave system.
Figure 10: this figure showing the components used in the master and slave devices
Figure 11: this figure showing the communication process between devices
Figure 12: it was showing app and SMS Views similar to figure 3
Figure 13: this figure showing the Screw & clamp based device which is easy to set on bogie in minute
Figure 14 & 15: figure 14 showing device installation arrangement on FIAT Bogie And figure 15 Showing installation arrangements in ICF type bogie.
Figure 16: this figure showing that there is an extra clamp battery power backup in the Device for emergency use this battery can be easily removed and can be replaces easily.
Further, skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have necessarily been drawn to scale. For example, the flow charts illustrate the method in terms of the most prominent steps involved to help to improve understanding of aspects of the present invention. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.
DETAILED DESCRIPTION OF THE INVENTION
For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same.
It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skilled in the art to which this invention belongs.
The system, methods, and examples provided herein are illustrative only and not intended to be limiting.
Embodiments of the present invention will be described below in detail with reference to the accompanying drawings.
RTTCMS is an Artificial Intelligence based Device fitted on the Bogie of Train for real time monitoring and prediction of upcoming failures in the Wheels, Rail Break & damages and other Bogie Parts and provide their Health Status on the Smartphone of Workers to Avoid Dangerous Accidents and Money losses.
During the whole journey of train, RTTCMS device regularly records the change in the data like- Tri-axial vibration of bogie parts, Angular movement of parts, their temperature, sound level at each point of journey (due to rail wheel contact & bogie parts), speed and Location of train, fracture figures by High speed resolution camera inbuilt in it, date & time when data recorded, remote controlling of machine and many more things gets recorded each second during whole journey of train.
After analysing these recorded data, RTTCMS Predicts the upcoming failure on rail, wheel or bogie parts and immediately send an Emergency alert on the smartphone of workers to repair that location immediately so as to avoid accidents and losses.
In future, this device will also be used as network relay for advertisement of local famous products through screen fitted inside the passenger trains.
This Artificial intelligence based device will play a great role to stop Railway Accidents and make the train to operate at very high speed and provide a safe & comfortable journey.
This device will reduce a big burden of Monitoring & Maintenance of Railway tracks and bogie parts.
After installation of this device Gang mans and Track mans do not have to move many kilometers on Railway track daily for manual monitoring, all the upcoming damaged location will be informed via their mobile phones, they only have to check only those particular location as device will inform on mobile, it will save the time and effort of workers.
Also, there are many local advertisement-based features in it for passengers through smart screen fitted inside the coach which will generate a huge revenue for Railways.
Solving Railway Problems:
Flat Wheel Detection:
Day wise change in the recorded data of Bogie fitted RTTCMS devices are able to predict the Flat wheels by recording change in data like Vibrations, sounds and some more data during the rail wheel contacts.
Upcoming Rail Break detection:
Artificial intelligence based RTTCMS devices are able to predict the Upcoming Failure on the Railway track so as to avoid accidents and losses
Bogie Parts Health Monitoring:
Our RTTCMS device fitted on the bogie and regularly records & analyse the health of bogie parts like- Bearing & Axle temperature, Vibration in different bogie parts, Angular movement of different bogie parts during the motion, speed, location & time of bogie, etc. and send all the recorded information on the smartphone of workers for live monitoring
Features of RTTCMS:
1. Flat wheel detection
2. Rail break detection
3. Tri-Axial Vibration of bogie parts
4. Angular movement of bogie parts
5. Sound level generated by bogie parts and rail-wheel contact
6. Temperature monitoring of bogie parts like- Bearing, Axle, wheels, etc.
7. Speed of Train
8. Location of train
9. Time & Date
10. Remote controlling of machine
11. Upcoming Failure prediction
12. Self Calibration
13. Inbuilt battery
14. Can be installed in all type of Wagons
15. Live Update on the smartphone of workers, about health of bogie
16. Send SMS & call to workers during emergency situation
Working Principle:
Working of RTTCMS Devices are in the form of a relayed MASTER and SLAVE based Communication. All the RTTCMS Devices are sensor based system and communicate with each other and smartphone of workers with 3 different type of networks, I.e. Local wireless networks (LPWAN/LoRa), Cellular network (GSM) and Satellite communication.
In which the slave RTTCMS devices are fitted on each bogie of train and the master RTTCMS device fitted in the locomotive or middle of train. All the slave devices record the data and send it to master device for analysis on recorded data, so that master device can predict the type of Upcoming failure. After predicting the type of failure master device immediately sends an SMS & Call on the smartphone of workers for alert and also update about the situation on the Cloud based mobile app. The SMS & app contains all the information about the type of Upcoming failure with proper location, date and time.
DEVICE TYPE & INTERNAL ARRANGEMENTS:
The internal arrangements of master and slave device is shown in figure 10
COMMUNICATION BETWEEN MASTER AND SLAVE DEVICES
Slave devices are transferring there recorded data to the master device.
After data analysis master device transfer the analysed health status of machinery parts on the cloud server & smartphone via GSM & GPRS network.
Purpose of Using device:
The device having two purpose of use:
1. For Monitoring only:
In monitoring part workers will be able to monitor the slave data on there smartphone, they have to manually analyse the day by day deformation changes on track or wheels or bogie parts, they have to manually predict the type of failure.
No Automatic Upcoming Future failure prediction in machine. But good & simple monitoring of data on Smartphone.
2. For Upcoming future failure prediction:
Its an Advance feature of RTTCMS device in which the type of failure will be predicted by Master RTTCMS device itself. All the analysis and future failure prediction will be done by master device itself. This system will gives the exact problem happened are going to happen with proper location and time.
Workers only have to go to the location and repair the problem. rest of the things will be done by master RTTCMS device itself.
Device fitting installation & commissioning:
The device is very easy to install in the bogie frame of train through loosing and tighten its screws.
RTTCMS Devices can easily be installed in the different type of train bogie like- FIAT, ICF etc. as shown in the figure:
Sliding Clamp based battery attachable & removable system in device figure:
The device is inbuilt with a sliding clamp based battery which can be easily attached and removed by new charged battery within a seconds. It smart battery replacement system will save the time of workers at the railway station and in emergency situations. This battery will work in emergency situation.
Although, There is an External battery charging and powering system is available in the Device.
Part wise Explanation of working
1. Slave RTTCMS devices fitted on bogie:
Slave devices are fitted on each bogie of train and designed by many no. of sensors, transmitters, receivers, microprocessors, memory cards, GPS, GSM,etc.
During the movement and static situation of train, Slave devices regularly records the data like- tri axial Vibration & Angular rotation of bogie, sound level during movement, temperature & location of wheels & bogie parts, time & date and many more data.
And send all those recorded data to the Main Master RTTCMS device through local Transceivers. Now all the further work will be done by Master Device.
2. Master RTTCMS Device:
Master RTTCMS Device is fitted on any bogie at the middle of Train or inside the Locomotive. Again Master device having similar Design like slaves but having many advanced features in it like- Networking modules, memory cards, data analysis system and many more things.
Master device receives the recorded data from different slave devices and make a combined analysis of different slave data.
After analysis master device produces a final values, and health status and Upload it to the server.
In case of any emergency, immediately an call & SMS will be sent on smartphone of workers by communicating nearby GSM & GPRS Networks.
It having a Special role of memory card in built in it, explained below.
3. Special role of Memory card in master device:
In case of network unavailability, all the data will be stored in the memory card inbuilt in Master device and when it will connected with network it will automatically upload on server and delete data from memory card.
4. Wireless Communication system:
The Communication between master and slave devices fitted in train are locally through Transceivers.
And the Communication between master and User Smartphone & Computer is Via GSM and GPRS.
5. Power Saving Mode
The device will be Strongly active when recording irregular data
But, will be in power saving mode when receiving smooth and safe data below threshold limits.
Best method of working and advantages:
1. Prediction of Master device - Failure is exactly in rail track : Let us consider the train passing through location X (position X), before X point the data was coming smoothly in 1st slave device of bogie. But when crossed X point, it read’s a High amplitude jerk at that point and again data coming smoothly after crossing that point. When 2nd slave device passed, again same situation happened in 2nd one And similarly in 3rd, 4th and next one.
Means, problem is only at that location X point. In this way the master device algorithm will detect the rail Fractures.
2: Prediction of Master device - Flat wheel of Bogie parts fractures: If the master device receiving smooth data from all the bogie Slave devices but from one bogie Slave device, master device is receiving Irregular data. Means, there is something problem in that particular bogie only.
After analyzing the different data , master device will predict the type of failure from flat wheel or other bogie parts.
3: Tracing of wheels and tracks : The devices are inbuilt with gyroscope and magnetometer which reads the Angular movements & directional rotation of wheel or bogie parts and analyse the direction of problem. With the help of these data and some other data device exactly detects that problem happened in that particular wheel or bogie parts or Track.
4: Future prediction of failure: a big fracture in wheel or track or other bogie parts does not happened suddenly, it start from a very small fractures and increases day by day. Our master device regularly records the Increase in these fractures. Master device regularly analyzes these increments and by Artificial Intelligence and data analysis it predicts the expected time at which the fracture will be above a safe & threshold value. And according to analysis it send mobile text message and alert on cloud server.

WE CLAIM

A real time train condition monitoring system (RTTCMS) comprises a master device and slave device which include microprocessor (101), Transceiver (102), RTC(103), GPS/GSM (104), Accelerometer (105), Proximity Sensor (105), Gyroscope (106), Magneto meter (107), Sound Sensor (108), Thermal Scanners (109), memory card (110), relay (111) , battery (112) and camera (113);
wherein RTTCMS is an Artificial Intelligence based Device fitted on the Bogie of Train for real time monitoring and prediction of upcoming failures in the Wheels, Rail Break & damages and other Bogie Parts and provide their Health Status on the Smartphone of Workers to Avoid Dangerous Accidents and Money losses.
2. The system as claimed in claim 1, wherein during the whole journey of train, RTTCMS device regularly records the change in the data like- Tri-axial vibration of bogie parts, Angular movement of parts, their temperature, sound level at each point of journey (due to rail wheel contact & bogie parts), speed and Location of train, fracture figures by High speed resolution camera inbuilt in it, date & time when data recorded, remote controlling of machine and many more things gets recorded each second during whole journey of train; wherein after analysing these recorded data, RTTCMS Predicts the upcoming failure on rail, wheel or bogie parts and immediately send an Emergency alert on the smartphone of workers to repair that location immediately so as to avoid accidents and losses.
3. The system as claimed in claim 1, wherein working of RTTCMS Devices are in the form of a relayed MASTER and SLAVE based Communication; and all the RTTCMS Devices are sensor based system and communicate with each other and smartphone of workers with 3 different type of networks, i.e Local wireless networks (LPWAN/LoRa), Cellular network (GSM) and Satellite communication.
4. The system as claimed in claim 1, wherein the slave RTTCMS devices are fitted on each bogie of train and the master RTTCMS device fitted in the locomotive or middle of train and all the slave devices record the data and send it to master device for analysis on recorded data, so that master device can predict the type of Upcoming failure; and after predicting the type of failure master device immediately sends an SMS & Call on the smartphone of workers for alert and also update about the situation on the Cloud based mobile app; and the SMS & app contains all the information about the type of Upcoming failure with proper location, date and time.
5. The system as claimed in claim 1, wherein the system is inbuilt with a sliding clamp based battery which can be easily attached and removed by new charged battery within a seconds; and smart battery replacement system will save the time of workers at the railway station and in emergency situations; and this battery will work in emergency situation.
6. The system as claimed in claim 1, wherein Slave devices are fitted on each bogie of train and designed by many no. of sensors, transmitters, receivers, microprocessors, memory cards, GPS, GSM; and during the movement and static situation of train, Slave devices regularly records the data like- tri axial Vibration & Angular rotation of bogie, sound level during movement, temperature & location of wheels & bogie parts, time & date and many more data; and send all those recorded data to the Main Master RTTCMS device through local Transceivers. Now all the further work will be done by Master Device.
7. The system as claimed in claim 1, wherein master RTTCMS Device is fitted on any bogie at the middle of Train or inside the Locomotive; and again Master device having similar Design like slaves but having many advanced features in it like- Networking modules, memory cards, data analysis system and many more things; and master device receives the recorded data from different slave devices and make a combined analysis of different slave data.; wherein after analysis master device produces a final values, and health status and Upload it to the server.
8. The system as claimed in claim 1, wherein in case of any emergency, immediately an call & SMS will be sent on smartphone of workers by communicating nearby GSM & GPRS Networks; wherein in case of network unavailability, all the data will be stored in the memory card inbuilt in Master device and when it will connected with network it will automatically upload on server and delete data from memory card.
9. The system as claimed in claim 1, wherein The Communication between master and slave devices fitted in train are locally through Transceivers; and the Communication between master and User Smartphone & Computer is Via GSM and GPRS.
10. The system as claimed in claim 1, wherein the system is inbuilt with a sliding clamp based battery which is easily attached and removed by new charged battery within a seconds; said smart battery replacement system saves the time of workers at the railway station and in emergency situations; which also works in emergency situation.